Fireproofing Specification

FIREPROOFING SPECIFICATION
FOR THE
CARTAGENA REFINERY
EXPANSION PROJECT
CB&I CONTRACT NO. 166000

Prepared By: Mechanical Engineering, Houston, TX
Document No: 166000-000-SP-MU10-0019
Information Class: Confidential Business Public
Revision Revision Revision Description Prepared Checked Approved
Number Date By: By: By:
0 24-Mar-08 ISSUED FOR DESIGN TAA KRS KRS

1 25-Jun-08 ISSUED FOR DESIGN TAA SAA IAR
2 27-Feb-09 ISSUED FOR DESIGN DD JB HT
3 29-Apr-09 ISSUED FOR DESIGN DD JB HT
4 29-Jun-10 ISSUED FOR DESIGN DD JB KDB
5 07-Oct-10 ISSUED FOR CONSTRUCTION DD JB GAD
6 07-Jan-11 ISSUED FOR CONSTRUCTION DD/JBB KDB GAD
Incorporated Client’s Comments
7 29-Jul-11 ISSUED FOR CONSTRUCTION DD/JBB KDB GAD
Included Pitt-Char Fireproofing per Client’s
request
THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY ("CB&I"). IT MAY CONTAIN INFORMATION DESCRIBING TECHNOLOGY OWNED BY CB&I AND
DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR
ANY PURPOSE OTHER THAN WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED AGAINST
BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY.
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TABLE OF CONTENTS
1.0 INTRODUCTION.......................................................................................................................3
1.1 Purpose ........................................................................................................................3
1.2 Scope............................................................................................................................3
1.3 Seller Responsibility....................................................................................................3
2.0 REFERENCES..........................................................................................................................3
2.1 International Protective Coating / Akzo Nobel ...........................................................4
2.2 PPG ...............................................................................................................................4
3.0 DEFINITIONS............................................................................................................................4
3.1 Hazardous Equipment and Piping ..............................................................................4
3.2 Hazardous Area............................................................................................................5
3.3 Fire Protection (Fire rating) .........................................................................................5
4.0 REQUIREMENTS .....................................................................................................................5
4.1 Extent of Fireproofing..................................................................................................5
5.0 PAINTING .................................................................................................................................7
6.0 MATERIAL................................................................................................................................7
6.1 Concrete or Lightweight Concrete: Form Placed Method and Pneumatically
Applied .........................................................................................................................7
6.2 Lightweight Cementitious Products ...........................................................................8
6.3 Intumescent Mastic (See Appendix A and B for Material Requirements) ................8
6.4 Reinforcement..............................................................................................................9
6.5 Waterproof Mastic........................................................................................................9
7.0 INSTALLATION ........................................................................................................................9
7.1 Concrete Fireproofing .................................................................................................9
7.2 Lightweight Cementitious Fireproofing....................................................................10
7.3 Intumescent Mastic Fireproofing (See Appendix A and B for Application
Requirements)............................................................................................................10
8.0 WORKMANSHIP ....................................................................................................................11
8.1 Preparation.................................................................................................................11
8.2 Curing .........................................................................................................................11
ATTACHMENTS.................................................................................................................................11
APPENDIX A – APPLICATION OF INTUMESCENT FIREPROOFING ............................................17
APPLICATION OF CHARTEK 1709...................................................................................................17
APPENDIX B – APPLICATION OF INTUMESCENT FIREPROOFING ............................................33
APPLICATION OF PITT-CHAR XP ....................................................................................................33
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1.0 INTRODUCTION
1.1 Purpose
The intent of this standard is to establish a guide for determining which structural steel supports
and equipment supports should receive fire protection with the objectives of minimizing danger
to personnel fighting fire, spread of fire and damage to process equipment.
1.2 Scope
This specification together with the referenced engineering drawings covers the minimum
requirements for the materials and application of fireproofing for hazardous equipment, structural
steel elements, power and instrument cables and control valves within fire hazardous areas of
the plant.
1.2.1 Fire proofing material for structural steel members shall be Chartek 1709 or Pitt-Char
XP. Appendix A and Appendix B are added to this specification to cover requirements
for application of both intumescent fireproofing.
1.2.2 All structural steel including module steel shall receive intumescent mastic fireproofing
(See Appendix A and Appendix B).
1.2.3 Vessel skirts and saddles shall be fireproofed with normal weight concrete.
1.3 Seller Responsibility

1.3.1 Any conflict between the requirements of this specification and related codes, standards,
data sheets, drawings, requisition, etc., shall be referred to Purchaser for
clarification/resolution.
1.3.2 Supplier shall not make assumptions for information not furnished by Purchaser.
Supplier is required to obtain necessary information from Purchaser or other reliable
sources. Any and all claims arising from lack of knowledge of required information will
be rejected by Purchaser.
1.3.3 Exceptions or variations shown in the Project Specifications take precedence over
requirements shown herein. No variations from the Project Specification and this design
standard are permitted unless approved in writing.
2.0 REFERENCES
Codes and Standards
The following documents, including applicable addenda, constitute a part of this specification as
described herein. The referenced edition of these documents shall be that which is in effect as of the
issue date of this specification.
API American Petroleum Institute

Publ 2218 Fireproofing Practices in Petroleum and Petrochemical Processing
Plants-Second Edition
ACI American Concrete Institute
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Std. 318 Building Code Requirement for Reinforced Concrete

Std. 506 Guide to Shotcrete
ASTM American Society of Testing and Materials
C33 Specification for Concrete Aggregates
C150 Specification for Portland Cement
D695 Test Method for Compressive Properties of Rigid Plastics
D790 Test Method for Flexural Properties of Unreinforced Plastics & Electrical
Insulation
D2240 Test Method for Rubber Properties – Durometer Hardness
D4541 Test Method for Pull-Off Strength of Coatings Using Portable Testers
E84 Test for Surface Burning Characteristics of Building Materials
UL Underwriters Laboratories
UL 1709 UL Standard for Safety Rapid Rise Fire Tests of Protection Materials for
Structural Steel-Third Edition, Reprint with Revisions Through and
Including April 6, 2007
SSPC Steel Structures Painting Council
AB-1 Abrasive Grade 1 or 2
PA-2 Measurement of Dry Paint Thickness with Magnetic Gages
SP-1 Solvent Cleaning
SP-6 Commercial Blast Cleaning
SP-7 Sweep Blast Cleaning
SP-10 Near-White Blast Cleaning
2.1 International Protective Coating / Akzo Nobel

C1709 APP MAN UK, Rev.0 Application Manual for Chartek 1709
Fire Protection QC MAN GB, Rev. 4 Quality Control Manual for Chartek Fireproofing
Systems Application
2.2 PPG
Pitt-Char XP Project Application Manual
3.0 DEFINITIONS
3.1 Hazardous Equipment and Piping

Hazardous equipment and piping is defined (for fireproofing) as that which contains material that
is flammable, toxic or dangerous to personnel.
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Equipment such as vessels, exchangers, tanks, drums, fin fan coolers and piping which contain
hydrocarbon is considered hazardous.
Internal combustion engines, pumps, and compressors are considered nonhazardous.
3.2 Hazardous Area

A hazardous area is defined as any area within 30 ft (9.2 m) horizontally and 30 ft (9.2 m)
vertically of a potential source of fire. Fire hazardous area for each unit is defined in the Project
Fire Hazardous Area Drawings.
3.3 Fire Protection (Fire rating)

The hours of protection are defined as the number of hours of exposure to rapid rise fire (UL
1709) while maintaining steel temperature below 1000° F (538° C) unless otherwise specified.
4.0 REQUIREMENTS
4.1 Extent of Fireproofing

4.1.1 Structural Steel
 When supporting fire potential equipment within the battery limits, columns
and the beams transmitting the equipment load to the columns shall be
fireproofed from their bases to the height of fire potential equipment or 30
feet (9.2 meters) above grade, whichever is greater. Fireproofing in this area
shall have a 2-hour, UL 1709 (typical), rating.
 All bracing carrying vertical loads shall be fireproofed when it is part of a
fireproofed supporting system. Bracing used only for wind loading shall not
be fireproofed.
 Platforms, runways, stairways, and their supports shall not be fireproofed
 The top flange of structural steel beams that support fire potential equipment
shall not be fireproofed.
4.1.2 Pipe Racks
 Both the vertical and transverse horizontal members of the first level of pipe
racks located within 30 feet (9.2 meters) of fire potential equipment shall be
fireproofed. Fireproofing in this area shall have a 2-hour rating. Pipe rack
structures more than 30 feet (9.2 meters) from any fire potential equipment
normally would not need fireproofing unless unusual conditions of exposure
or loading exist. Beams parallel to the pipe shall not be fireproofed.
 If air cooled exchangers are installed above pipe racks, the upper transverse
levels of the pipe racks shall be fireproofed including the full height of the
vertical columns. All horizontal structural members supporting air cooled
exchangers, including those cantilevered beyond the vertical supports, shall
be fireproofed.
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 Knee braces and tee supports bearing heavy or critical piping shall be
fireproofed.
 The top flange of pipe bearing beams shall not be fireproofed
4.1.3 Equipment Supports
 All lugs, brackets, skirts, and legs supporting fire potential equipment located
within the fire potential area shall be fireproofed.
 Saddles supporting equipment and measuring more than 1 foot (310 mm) in
height at their lowest points shall be fireproofed within the fire potential area.
 Fireproofing in this area shall have a 2-hour rating.
4.1.4 Skirts Supporting Fire Potential Equipment
 The outside of skirts supporting process vessels shall be fireproofed.
 The inside of skirts over 4 feet (1.2 meters) in diameter.
 Skirts 4 feet (1.2 meters) and less in diameter shall not be fireproofed on the
inside.
 Skirts which require insulation shall be fireproofed on the uninsulated
portions only.
4.1.5 Heaters
 Structural members supporting fired heaters above grade should be
fireproofed for heaters handling flammable or combustible liquids. Structural
steel members supporting fired heaters in other services should be
fireproofed if located within a fire-scenario area. These include fired heaters
in other-than hydrocarbon service, such as steam superheaters or catalytic
cracking-unit air heaters, if a collapse would result in damage to adjacent
hydrocarbon-processing equipment or piping.
 If structural support is provided by horizontal steel beams beneath the
firebox of an elevated heater, fireproofing should be considered for the
beams, unless at least one flange face is in continuous contact with the
elevated firebox.
4.1.6 Reboilers
Supporting lugs and steel supporting reboilers shall be fireproofed. All beams and
columns supporting reboilers shall be fireproofed regardless of the elevation of the
reboilers.
4.1.7 Electric Power and Instrument Cable
Electric, instrument, and control systems used to activate equipment needed to control a
fire or mitigate its consequences (such as emergency shutdown systems and isolation
valves) should be protected from fire damage, unless they are designed to fail-safe
during a fire exposure. If the control wiring used to activate emergency shutdown
devices (including depressurization or isolation system) during a fire could be exposed
to the fire, the wiring should be protected against a 15 minute fire-exposure functionally
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equivalent to the conditions of UL 1709. If activation of these emergency systems would

not be necessary during any fire to which it might be exposed, then protection of the
wire is not required for emergency response purposes.
The primary methods of avoiding early cable failure in a fire situation that could prevent
the safe shutdown of a plant include the following:
a. Locate isolation and emergency valves outside fire potential area
b. Burying cable below grade
c. Routing cable around areas that have a high fire potential
d. The use of fireproofed cable trays/conduits
e. The use of L.V. “Fire Resisting” cables
4.1.8 Pneumatic and Hydraulic Instrument Lines
Pneumatic and hydraulic instrument lines shall be protected for the same reason as
described in 4.1.7. If Pneumatic and hydraulic instrument lines are from the stainless
steel tubing which is highly resistant to failure during a hydrocarbon fire and do not have
to be fireproofed with insulating material.
4.1.9 Control Valves
The control valves and their activators that should operate during a fire should be
protected by various insulating systems that use preformed fire resistant material such
as:
a. K-Mass
b. Lace-up fire resistance blankets
c. Insulation with stainless steel jacketing
The control valves should be protected against a 15 minute fire-exposure functionally
equivalent to the conditions of UL 1709.
5.0 PAINTING
5.1 Prior to fireproofing, all surfaces shall be coated per the coating specification. Concrete
fireproofing shall be applied directly over galvanized steel. For intumescent fireproofing
material, manufacturer’s recommendation and requirements in Appendix A or Appendix B shall
be followed.
5.2 All studs or clips welded to the steel surface shall be spot cleaned and touch-up primed.
5.3 Prior to fireproofing, all surfaces shall be free of dirt, grease and coating holidays.
6.0 MATERIAL
6.1 Concrete or Lightweight Concrete: Form Placed Method and Pneumatically Applied
6.1.1 Concrete for both manual and pneumatic placement shall be mixed in the proportion as
determined by the applicator in accordance with Supplier’s recommendation so as to
obtain a minimum compressive strength of 2000 psi at 28 days. Water/cement ratio shall
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not exceed 0.50. Ready-mixed concrete in accordance with ASTM Specification C94
may be used.
6.1.2 Thickness for concrete or lightweight concrete shall be 2 inches (50 mm) minimum.
6.1.3 Portland cement shall be in accordance with ASTM Specification C150.
6.1.4 Aggregate
 Form Placed Method
Fine and coarse aggregate shall conform to ASTM Specification C33 for
concrete and C330 for lightweight concrete. Maximum aggregate size shall
be limited to ½ in (13 mm).
 Pneumatically Applied
Fine aggregate (sand) shall conform to ASTM Specification C33 for concrete
and C330 for lightweight concrete. Maximum aggregate size shall be limited
to ¼ in (6.4 mm).
 Water shall be cold, clean and free of oils, acids, salts or other substances
injurious to the concrete. Water of drinkable quality is acceptable
6.2 Lightweight Cementitious Products

6.2.1 Commercial lightweight cementitious products are acceptable only when in compliance
with the following quality criteria. Ablative coatings, gypsum, and magnesium
oxychlorides are not acceptable.
6.2.2 Product must be listed by the Underwriters Laboratories, Inc., for exterior use based
upon testing in accordance with UL 1709.
6.2.3 Fireproofing material shall contain no asbestos, toxic, or “red label” solvents.
6.2.4 Fireproofing Supplier shall furnish a list of current installations utilizing the product in
question. This list shall contain the locations, type and years of service.
6.2.5 Lightweight products should not be used where structures are susceptible to mechanical
abuse (grade to 8 feet (2.44 meters) – use concrete only).
6.2.6 Lightweight cementitious material shall be Pyrocrete 241 as manufactured by Carboline
or approved equal.
6.2.7 Thickness for lightweight cementitious material shall the manufacturer’s
recommendation.
6.3 Intumescent Mastic (See Appendix A and B for Material Requirements)

6.3.1 Intumescent mastic material shall consist of a fibrated mastic material in ready mixed
form nonflammable when cured, durable under extreme weather conditions and suitable
for temperature to 250° F (121 °C). It is a proprietary material.
6.3.2 Thickness for intumescent mastic fireproofing shall be per manufacturer’s
recommendation.
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6.3.3 Intumescent mastic material shall be from the following manufacturer or approved equal.
 Chartek 1709 - manufactured by International Paint Ltd.
 Pitt-Char XP - manufactured by PPG
6.4 Reinforcement
6.4.1 Concrete or Lightweight Concrete Fireproofing
 Welded wire mesh shall be 2 in x 2 in (50 mm x 50 mm), 12/12 gauge.
 Annealed stainless steel wire shall be used for tie wire mesh where
necessary.
6.4.2 Lightweight Cementitious Fireproofing
2 2
 Metal lath shall be 3.4 lb/yd (1.84 kg/mg ) galvanized diamond metal lath.
6.4.3 Intumescent Mastic Fireproofing
 Reinforcement for Chartek 1709 – HK-1 (M) (hybrid carbon and glass
composite mesh).
 Reinforcement for Pitt-Char XP – Galvanized Steel Hardware Cloth ½” x ½”
x 19 gage
6.5 Waterproof Mastic

6.5.1 Waterproof Mastic shall be Pecora Silicone No. 864 or approved equal.
6.5.2 Primer shall be P-65 or approved equal.
7.0 INSTALLATION
7.1 Concrete Fireproofing

7.1.1 Concrete fireproofing shall be used for equipment supports (skirts, saddles, and legs).
Over light weight concrete, 8 ft of steel column from grade level, shall have two inch (50
mm) minimum thickness pneumatically applied or poured in place concrete.
 The concrete shall be held in place by wire mesh as defined below.
 Fireproofing need not be rubbed to a smooth finish, provided there is no
honeycombing.
 Fireproofing shall have the equivalent of a wood float finish.
 Any cracks wider than 1/16 in. (1.5 mm) shall be repaired.
7.1.2 Wire mesh shall be secured to studs or clips welded to the steel structure approximately
18 in. (450 mm) apart and shall be fastened approximately ¾ in. (19 mm) from the
surface of the steel work. Clips and studs shall not be longer than 1 in. (25 mm).
 A 3 in. (75 mm) minimum lap shall be used for joining wire mesh.
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 Seller shall add crimp rods on beams and columns as required to support
reinforcement for fireproofing materials.
7.1.3 Any unusual details such as reboiler supports necessary for applying fireproofing to
structural steel members shall be shown on the structural steel drawings.
7.1.4 All exposed concrete corners shall be chamfered or rounded.
Top surfaces shall be sloped for drainage. Exposed joints between steel and concrete
shall be sealed with waterproof mastic equal to Pecora Silicone No. 864 with the Pecora
P-65 primer.
7.1.5 All joints between fireproofing and steel shall be chipped or tooled and filled with a
sealing compound, Thiokol base sealant, Pecora sealant or authorized equal to prevent
the intrusion of moisture.
7.2 Lightweight Cementitious Fireproofing

7.2.1 Fireproofing of structural steel shall be with either concrete or lightweight cementitious
material. Thickness of the concrete shall be 2 in. (50 mm) minimum. Thickness of the
special material shall be per manufacturer’s recommendation.
7.2.2 When fireproofing is required for structural elements, all sides of the steel shape shall be
covered except the top flange of beams which support process equipment, flooring,
piping, etc.
7.2.3 Concrete fireproofing on all sides of beams and columns shall be applied in accordance
with Paragraph 7.1 of this specification.
2
7.2.4 Lightweight fireproofing material shall be held in place by 3.4 lb/yd galvanized diamond
metal lath.
7.2.5 A final surface resembling a wood float finish shall be considered satisfactory.
7.2.6 For columns and beams of contour design, naturally rounded off corners of proper
thickness are acceptable.
7.2.7 On columns and beams boxed design construction shall not be used.
7.2.8 Caulking and sealing shall be done with product listed in Section 7.1.4 and 7.1.5.
7.3 Intumescent Mastic Fireproofing (See Appendix A and B for Application Requirements)
7.3.1 Intumescent Mastic fireproofing shall be used only where required and shall be identified
by the Owner.
7.3.2 Intumescent Mastic fireproofing shall be installed as per manufacturer’s
recommendation by certified applicator only.
7.3.3 Manufacturer’s representative should be present at beginning of application and follow
up.
7.3.4 Surface preparation and primer coat shall be per manufacturer’s recommendation.
7.3.5 Top coat shall be applied as per manufacturer’s recommendation.
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8.0 WORKMANSHIP
8.1 Preparation
8.1.1 Overspraying on adjacent piping, equipment, instruments, aluminium metal surfaces,
etc. Is not acceptable. Seller shall protect all adjacent areas either by shielding by
masking or covering with plastic tarps. Seller shall be responsible for removing all
overspray fireproofing materials.
8.1.2 Fireproofing shall not be installed when temperature is below 40°F (5°C) or expected to
be below 40°F (5°C) in next 24 hours. Seller shall provide suitable means of heating the
newly installed fireproofing to a minimum of 40°F (5°C) for at least 24 hours after
placing. Substrate temperatures shall always be above 40°F (5°C) when fireproofing is
being applied.
8.1.3 Fireproofing shall not be installed during periods of high winds or rain.
8.1.4 Spot prime areas to be fireproofed where the shop preparation is damaged.
8.1.5 Steel members to receive fireproofing shall be cleaned, dried and made free of oil, dirt,
and other foreign material.
8.2 Curing
8.2.1 Fireproofing material shall be cured per Manufacturer’s recommendation and shall be
wetted as required to allow full curing.
8.2.2 Polyethylene film or wet burlap shall be used to retain moisture in curing of fireproofing
material.
ATTACHMENTS
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ATTACHMENT I
FIREPROOFING STEEL STRUCTURES
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ATTACHMENT II
STRUCTURAL STEEL PIPE AND EQUIPMENT SUPPORT
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ATTACHMENT III
FIREPROOFING DETAILS USING CONCRETE MATERIAL
4. WELDED WIRE MESH SHALL BE USED IN LIEU OF HEXAGONAL POULTRY MESH AS

STATED IN NOTE 3 ABOVE.
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ATTACHMENT IV
FIREPROOFING DETAILS USING SPECIAL MATERIALS
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ATTACHMENT V
FIREPROOFING DETAILS FOR VESSEL SKIRTS
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APPENDIX A – APPLICATION OF INTUMESCENT FIREPROOFING USING CHARTEK 1709

1.0 Scope
This appendix covers requirements for material and application of intumescent fireproofing.
1.1 Blockout areas for field connection including bolt holes shall not be fireproofed in the shop but
shall receive surface preparation and primer coat per this specification.
1.2 Blockout areas shall be kept to minimum. See structural steel drawings for the blockout details.
1.3 Installation details are shown in ATTACHMENT E
1.4 Top face of flange and top edges on beams supporting pipe and equipment shall not be
fireproofed. The entire beam shall be blast cleaned per Section 7.2 and primed with Intergard
251 per Section 8.3. Top face including the edges shall be masked off during fireproofing
application. All surfaces except top face and top edges shall be fireproofed with Chartek 1709
per this specification. The top face and edges (Non-fireproofed surface) shall receive one coat
of Interzone 954, 10 mils (250 mcrons) MDFT and top coat of Interthane 990, 2 to 3 mils (50 to
75 microns) MDFT, Interzone 954 and Interthane 990 shall be applied after Chartek application.
1.5 All horizontal finished surface of fireproofing such as column base plate, top face of bottom
0
flange on beams, etc. shall have 5 slope to prevent water ponding.
1.6 Fireproofing zone of galvanized columns shall be sweep blasted per Section 7.3 and primed with
Intergard 251 primer per Section 8.3 prior to application of Chartek 1709.
1.7 Galvanized bolt on bolted connection shall be solvent wiped and surface shall be abraded with
80 grit sand paper, dust removed prior to application of Intergard 251 primerand finish off with
Chartek 1709 and Interthane 990. This application can be combined with fireproofing of field
block outs.
2.0 Applicator’s Responsibility
Applicator QA/QC responsibilities as follows
a. Supply the equipment for the specified inspections and tests required for fireproofing activities.
b. Supply new and undamaged fireproofing materials received at the shop or field jobsite in the
manufacturer’s original sealed containers.
c. Proper storage of all materials in the area protected from weather before and during application
d. Inspection of fireproofing materials and accessories prior to commencement of work. Any material
that has been damaged or found to be defective shall be removed and replaced by the seller at his
expense.
e. Inspection during key construction phase include, proper storage of materials, surface preparation,
primer application, equipment setup and application (Chartek 1709), Installation of reinforcing mesh
(HK-1 M), Chartek 1709 thickness measurements and topcoat application
f. Applicator / Steel fabricator shall ensure that the applicator conforms to QC MAN GB, Rev.4. This
includes (Samples attached to this specification )
Chartek Fireproofing - Area Quality Control Report
Chartek Fireproofing Daily Log
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Chartek Fireproofing Equipment Quality Control Report

3.0 Manufacturer Responsibility
A technical service audit shall be conducted by the manufacturer during the initial start of fireproofing
and provide technical assistance during production phase.
4.0 Submittals
a. Applicator shall submit to the buyer a list of materials to be used in fireproofing and shall identify the
specific design mix including manufacturer’s datasheets and MSDS sheets.
b. Applicator shall submit written procedures for storage, handling, surface preparation, environmental
control, application, verification of fireproofing thickness, repair, and inspection of the fireproofing.
Procedures shall be submitted to Purchaser for review and approval prior to using them.
c. Subcontractor shall submit to Purchaser for review fireproofing verification forms as specified in
clause 2..0 (f). Daily inspection forms shall be accessible for spot review on a daily basis.
d. Fireproofing verification forms shall be used to verify that proper materials were used, and that
accepted application procedures and specifications were followed. Fireproofing verification forms
shall include a statement of completion conformance.
5.0 Materials
1. General
Fireproofing materials shall conform to C1709 APP MAN UK, Rev. 0
5.2 Primer
a. Primer shall be International Intergard 251
b. Mid coat for top face of flange on beam Interzone 954
c. Primer shall be approved and UL 1709 tested.
5.3 Chartek 1709
1. Fireproofing shall be CHARTEK 1709 manufactured by International Protective
Coating/Akzo Nobel.
2. CHARTEK 1709 shall meet the requirements of UL1709, per XR design rating.
3. Fire rating of CHARTEK 1709 shall be 2 hour per UL1709 in accordance with CHARTEK
1709 Design XR625
4. CHARTEK 1709 shall have the following minimum physical properties:
a. Dry density –62 lb/ft3
b. Compressive strength – 1,500 psi (determined in accordance with ASTM
D695)
c. Hardness – Shore D 55-65 (determined in accordance with ASTM D2240)
d. Flexural strength – 36,250 psi (determined in accordance with ASTM D790)
e. Flame spread – Class A 25 (determined in accordance with ASTM E84)
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f. Smoke developed – Class A 300 (determined in accordance with ASTM

E84)
g. Adhesion strength to steel – 1450 psi (determined in accordance with ASTM
D4541)
5. Testing shall be performed to determine physical properties for above items a, b, c, d,
and g.
5.4 Reinforcing Mesh
1. Reinforcing mesh shall be HK-1 (M) (hybrid carbon and glass composite mesh).
2. Reinforcing mesh shall be supplied by the mastic manufacturer.
5.5 Topcoat
1. Topcoat shall be international Interthane 990 or as specified by the mastic manufacturer. .
2. Finish color shall be Medium Gray per RAL 7004.
6.0 Preconstruction Activities
6.1 Preconstruction Meeting
1. Project Engineer shall arrange for a preconstruction meeting with the following individuals
in attendance:
a. Purchaser Project Engineer (primary project contact)
b. Purchaser Non Metallic Technologist
c. Purchaser Lead Civil Engineer
d. Purchaser QA/QC Inspector
e. Subcontractor representatives, including QC coordinator and foreman assigned to the
job
f. Contractor structural steel fabrication/erection representative
g. Manufacturer representative
2. Agenda to be covered at the preconstruction meeting shall include the following:
a. Review of Contractor’s submittals and this specification
b. Inspection hold points
c. Controls of environmental conditions in the shop
d. Condition of steel necessary to accept fireproofing
e. Surface preparation and compatible primer application
f. Fireproofing application, installation of reinforcement, and thickness measurements
g. Cure measurement prior to application of topcoat
h. Proper topcoat application
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i. Exposure to elements only after system is completely sealed

6.2 Sample Preparation and Adhesion Testing
1. Applicator shall prepare a fireproofing sample on a 6 ft. long W10x49 carbon steel beam.
The sample shall have pockets and tabs to represent complex shape.
2. Sample requires inspection and approval in writing by the Purchaser before the Applicator
proceeds with application of the fireproofing.
3. Sample shall illustrate correct fireproofing appearance, thickness, reinforcing, and surface
finish, and shall be used as the application standard.
4. Sample shall be tested for adhesion in accordance with ASTM D4541.
a. Adhesion of primer to steel or galvanizing shall be a minimum of 300 psi.
b. Adhesion of fireproofing to primer shall be a minimum of 300 psi.
c. Adhesion of topcoat to fireproofing shall be a minimum of 300 psi.
5. Owner or his representative, Contractor, Subcontractor, and Manufacturer shall approve the
sample.
6. Two random production pieces that are shop fireproofed shall also be tested for adhesion.
6.3 Area Inspection
Area that will receive fireproofing shall be inspected to verify that ducts, piping, equipment, or
other items that would interfere with application of fireproofing are not positioned until
fireproofing work is complete.
7. Substrate Inspection and Preparation
7.1 Inspection
1. Substrate shall be inspected to verify that it is ready to be cleaned/blasted.
2. Substrate shall be uniform and free of defects, such as weld deficiencies, lack of seal
welding, and poor drainage of galvanizing.
3. Any substrate defects that may adversely affect adhesion or performance of the fireproofing
shall be properly repaired.
7.2 Non-Galvanized Substrate
1. Non-galvanized substrate shall be blasted in accordance with SSPC SP-10.
2. Blasted substrate shall have an anchor pattern of 2.0 to 3.0 mils minimum.
3. Specific abrasive shall be determined by the Applicator and approved by the Manufacturer
prior to use.
7.3 Galvanized Substrate
1. Galvanized substrate shall be cleaned and degreased in accordance with SSPC SP-1.
Alkaline cleaners shall not be used.
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2. Cleaned substrate shall be blasted in accordance with SSPC SP-7/NACE No. 4. Abrasive
shall conform to SSPC AB-1.
3. Blasted substrate shall have an anchor pattern that is sharp with no evidence of a polished
surface.
8. Fireproofing Application
8.1 Ambient Considerations
1. Fireproofing shall be applied when:
a. Substrate temperature and ambient temperature are on the rise and greater than 50°F.
b. Ambient temperature is 5°F above the dew point.
c. Relative humidity is less than 85%.
2. Areas where fireproofing is applied shall be ventilated for 24 hours after application.
3. Work area shall be kept clean and well ventilated.
4. Spillage and over-spray shall be removed promptly before material has cured.
8.2 Protection of Adjacent Areas
1. Adjacent equipment and surfaces that will not be fireproofed shall be protected from damage
by over-spray, fall-out, or dusting.
2. Ducts in areas where fireproofing is being applied shall be closed and sealed.
8.3 Primer Application
1. Primer shall be applied to a dry film thickness (DFT) of 2 to 3 mils. Maximum allowable DFT
on overlaps shall be 3 mils.
2. For non-galvanized substrate, primer shall completely cover the blast profile.
3. Prior to application of primer, on galvanized substrate, excessive zinc thickness may be
reduced by sanding with P80-P-100 grade aluminum oxide abrasive paper for small areas.
Polishing shall be avoided. For large surfaces, galvanized surface shall be sweep blasted
per SSPC-SP7
8.4 CHARTEK 1709 Mixing
1. Properly mixed CHARTEK 1709 is light gray (with no striping).
2. A quality control check for mixing shall be a ratio check, performed by the Subcontractor.
The ratio check shall be by weight as follows:
a. Weigh clean empty Parts A and B containers and note the respective weight.
b. Place the container under the ratio check valves located on the mixing block and open
the valve at exactly the same time.
c. Close the valves when the containers are at least half full at exactly the same time.
d. Calculate the ratio of Part A and Part B as a percentage of the total weight. Example
Part A to Part B ratio is 2.5:1.
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3. A minimum of two ratio checks shall be performed per shift, (1) start of the shift and (2)
when the pump is shut down and restarted.
8.5 CHARTEK 1709 Application
1. Primer shall be allowed to cure for a minimum of twelve hours at 77°F before the CHARTEK
1709 is applied.
2. Before CHARTEK 1709 is applied, primed substrate shall be cleaned of dirt, dust, grease,
oil, loose material, or other matter that may adversely affect CHARTEK 1709 bond.
3. CHARTEK 1709 shall be applied in accordance with APP MAN C1709, Rev 0.
4. CHARTEK 1709 materials shall be kept within a temperature range of 86˚F to 93˚ F for 24
hours prior to use.
5. CHARTEK 1709 shall be applied using plural component spray equipment. Equipment
suppliers recommended by the Manufacturer are as follows:
a. Spray-Quip, Inc., 1754 Des Jardines, Houston, TX 77023 – Herb Chilman, Sr., 800-500-
9109
b. Airtech Spray Systems, Inc., 4303 Pinemont, Houston, TX 77018 – Joe Acosta, 713-
681-0013
6. Operating parameters for plural component spray equipment shall be in accordance with
APP MAN C1709, Rev 1.
7. CHARTEK 1709 shall be applied to a minimum thickness of 10.7 mm per BYBU. XR 625 for
2 hour rating (UL 1709 certification directory).
a. Minimum thickness at any one point shall not be less than 85% of specified thickness.
b. Overall average thickness shall be equal to, or greater than, the UL specified thickness.
c. UL certified thickness is based on the average thickness.
8.6 Reinforcing Mesh Application
1. Reinforcing mesh shall be cut to required size before CHARTEK 1709 is applied.
2. Mesh shall be rolled thoroughly into the wet CHARTEK with short nap roller lightly
dampened with International PMA solution.
3. Adjacent pieces of mesh shall be overlapped by a minimum of 2 in.
4. Mesh shall be placed at approximately mid thickness of the CHARTEK 1709.
5. Mesh shall be applied over flanges as shown on the details.
6. Mesh also shall be installed over web if web span is greater than 10 inches or as
required per manufacturer’s application procedure.
8.7 Topcoat Application
1. Topcoat of Interthane 990 shall be applied in accordance with APP MAN C1709, Rev 0.
2. Unless otherwise specified, topcoat shall be applied within seven days after the CHARTEK
1709 is applied. If the seven days are exceeded, the surface of the CHARTEK 1709 shall be
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sweep blasted or mechanically abraded with 40 grit paper (or equivalent) and solvent
cleaned prior to applying the topcoat.
3. Topcoat shall be applied to a minimum DFT of 2 to 3 mils.
9. Inspection, Testing, and Repair
9.1 Daily Production Samples and Tests
1. Daily production samples shall be taken one per shift. Additional samples shall be taken if
material batch numbers change. This can be accomplished by spraying material into a
plastic cup and identifying sample number and date.
a. Samples shall be tested randomly to determine fireproofing hardness and density
properties.
b. Sample shall be documented on the CHARTEK Fireproofing Daily Log.
2. The following inspections and tests shall be performed on a daily basis.
a. Degreasing stage – surface contamination – Visual, white cloth check for oils or other
harmful contaminates [SOVENT WIPE TEST]
b. Blast cleaning – Visual inspection to ensure sheen surfaces are dulled by sweep
blasting steel [VISUAL]
c. Primer – Wet film thickness measurements primer [WET FILM GAGE]
d. Inspect spray equipment – Operating conditions of plural component equipment
[MATERIAL RATIO WEIGHT CHECK]
e. Application of CHARTEK 1709 – Inspect wet film thickness with approved [WET FILM
GAGE Internationals Thickness Gauge ], observe mesh installation
f. CHARTEK 1709 dry film thickness test [approved electronic meter Ecometer Model 456
or 355 with either F3 or F6 probe]
g. Inspect cure of CHARTEK 1709 – [DUROMETER SHORE D]
h. Topcoat – Inspect application of topcoat [WET FILM THICKNESS]
i. Environmental test equipment – Sling pychrometer, surface thermometer
9.2 Deficiency Inspection and Repair
1. Deficiencies in the fireproofing shall be inspected, noted, and properly repaired.
Deficiencies include, but are not limited to, the following:
a. Cracks of any length in CHARTEK 1709.
b. Disbondment of primer, CHARTEK 1709, or topcoat
c. Exposed reinforcing mesh
d. Inadequate fireproofing thickness.
e. Excessive mills and subsequent coating runs, drips, spills, and curtains.
2. Repair of deficiencies shall conform to Section 10.0 of APP MAN C1709, Rev 0. If
necessary, Manufacturer shall write repair procedures not covered in APP MAN C1709.
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3. A written repair procedure shall be submitted to the Purchaser before repairs are performed.
9.3 Hardness Test
1. CHARTEK 1709 shall be given a Shore D Hardness test 48 hours after CHARTEK
application and before application of the topcoat.
2. Shore D Hardness test shall be performed using a Durometer gauge.
3. CHARTEK 1709 shall have a minimum hardness of 40 Shore D.
4. Hardness readings shall be taken on areas that are relatively smooth.
5. Ten readings shall be taken per area, discarding the low and high reading.
9.4 Density Test
1. Random daily production samples (see 8.1) of CHARTEK 1709 shall be tested for density a
minimum of once per week.
3
2. CHARTEK 1709 shall have a minimum density of 62 lbs./ft .
9.5 Final Inspection
Final inspection of the installed fireproofing shall be performed jointly by the Applicator and the
Purchaser.
9.6 Test Results
Test results shall be recorded on “CHARTEK Fireproofing –Area Quality Control Report” and the
“Fireproofing Daily log”.
10. Curing
Fireproofed surfaces shall not be exposed to the exterior elements until the fireproofing is completely
cured and the topcoat is properly sealed over the entire fireproofed surface.
11. Shipping and Handling
All fireproofed steel shall be handled using nylon slings or other approved lifting methods. Proper
dunnage during transport, storage and jobsite erection shall be used to minimize damage to the
fireproofing.
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ATTACHMENT A – CHARTEK® FIREPROOFING – AREA QUALITY CONTROL REPORT
Project: Owner:
Owner’s representative: Applicator’s representative:

Area identification: see attached drawing
Report Nº: XXX – A Date: Prepared by:
OPERATION DATE Nº TEST ACTIVITY SIGNATURE SITE COMMENTS

(see QCP nº XXX) MANAGER/QC
BLAST CLEANING-PRIMER-MASKING
Blast cleaning-
primer
Acceptance of
surfaces
Masking
Sample area
CHARTEK APPLICATION-MESHING
1st Coat
Mesh installation
2nd Coat
TOPCOAT
1st Coat
2nd Coat
NOTES
AREA COMPLETE
Applicator: Signature: Name:
Owner: Signature: Name:
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ATTACHMENT B-CHARTEK® FIREPROOFING DAILY LOG

PERSONNEL
Project: Owner:

Report Nº: XXX - B Date: Prepared by:
Site Manager:
Site QA/QC Manager:
Sprayers-trowellers:
Owner’s QC Inspector:
ENVIRONMENTAL CONDITIONS (to be recorded every hour)
Time
Ambient temp.
Relative humidity
Dew point
Substrate temp.
MESH INSTALLATION
Mesh installed (type and surface area in m2):
Edge mesh (Charlok) installed (linear meters):
CHARTEK STORAGE TEMPERATURE Part A Part B
CHARTEK APPLICATION
Ratio (% in A.M. Part A Part B P.M. Part A Part B
weight)
SPRAY EQUIPMENT ID (type and serial number):
ID areas coated (if different
from drawing)
Specified thickness (mm)
Thickness applied to date
Thickness applied today
Surface area coated (m2 )
Chartek quantity used (no. of kits) Part A Part B Solvent used : Type Quantity (lt.)
CHARTEK BATCH NUMBERS
Part A:
Part B:
NOTES
Signature Site Manager-Site QA/QC Manager:
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ATTACHMENT C- CHARTEK® FIREPROOFING EQUIPMENT QUALITY CONTROL REPORT
Project: Owner:
Report Nº: XXX – C Date: Prepared by:
PLURAL COMPONENT SYSTEM

Machine type
Hose length
Preloading Chartek temperature Part A: Part B:
Tank temperatures Part A: Part B:
Tank pressures Part A: Part B:
In-line heater temperatures Part A: Part B:
Displacement pump pressures Part A: Part B:

(at cylinder exit)
Line heat
Gun exit temperature
Spray gun Tip size (1/1000”): Fan size (mm):
NOTES
Signature Site Manager-Site QA/QC Manager:
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ATTACHMENT D – UL Certification of Chartek 1709
Fire Resistance Ratings - ANSI/UL 1709

See General Information for Fire Resistance Ratings -ANSI/UL 1709
Design No. XR625
October 09, 2006
Ratings - 1/2, 3/4, 1, 1-1/2, 2, 2-1/2, 3, 3-1/2 Hr. (See Item 3)
1 Steel Column — Min. size W10X49. The column surfaces shall be free of dirt, loose scale and oil then primed
with epoxy based primers to an approximate dry film thickness of 2 mils.
2 Flange Edge Reinforcement — Carbon fiberglass mesh Type HK-1 applied over the flange tips at
approximately mid-depth of the total thickness of mastic coating.
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3. Mastic Coating — Two component spray materials applied in one or more coats as described in the application
instructions to the thickness shown below. Thickness below includes 2 mils (50 micron) of
primer.
Material Thickness,
Material Thickness, Microns Microns
Rating, Hr With Mesh (Item 2) Without Mesh (Item 2)
1/2 - 2740
3/4 - 4550
1 - 5780
1-1/2 8240 -
2 10700 -
2-1/2 13160 -
3 15620 -
3-1/2 18080 -
INTERNATIONAL PAINT LTD — Type Chartek 1709. Investigated for exterior use.
4. Top Coat — One of the following topcoats shall be used. Two component polyurethane topcoat Type
Interthane 990 applied at a dry film thickness of 50 microns. Two component
polyurethane topcoat Type Interthane 990HS applied at a dry film thickness of 50
microns. Two component polysiloxane topcoat Type Interfine 878 applied at a dry film
thickness of 50 microns. Two component polysiloxane topcoat Type Interfine 979
applied at a dry film thickness of 100 microns.
*Bearing the UL Classification Mark
Last Updated on 2006-10-09
Copyright © 2007 Underwriters Laboratories Inc. ®
The appearance of a company's name or product in this database does not in itself assure that products so
identified have been manufactured under UL's Follow-Up Service. Only those products bearing the UL
Mark should be considered to be Listed and covered under UL's Follow-Up Service. Always look for the
Mark on the product.
UL permits the reproduction of the material contained in the Online Certification Directory subject to the
following conditions: 1. The Guide Information, Designs and/or Listings (files) must be presented in their
entirety and in a non-misleading manner, without any manipulation of the data (or drawings). 2. The
statement "Reprinted from the Online Certifications Directory with permission from Underwriters
Laboratories Inc." must appear adjacent to the extracted material. In addition, the reprinted material
must include a copyright notice in the following format: "Copyright © 2007 Underwriters Laboratories
Inc.®"
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ATTACHMENT E – Installation Details
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ATTACHMENT E – Installation Details (Continue)
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ATTACHMENT E – Installation Details (Continue)
Note: HK-1 (M) Mesh is required on web if web dimension is greater than 10 inches (250
mm) and as required per Chartek 1709 Application Manual.
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APPENDIX B – APPLICATION OF INTUMESCENT FIREPROOFING USING PITT-CHAR XP

1.0 Scope
This appendix covers requirements for material and application of intumescent fireproofing.
1.1 Blockout areas for field connection including bolt holes shall not be fireproofed in the shop but
shall receive surface preparation and primer coat per this specification.
1.2 Blockout areas shall be kept to minimum. See structural steel drawings for the blockout details.
1.3 Installation details are shown in ATTACHMENT E.
1.4 Top face of flange and top edges on beams supporting pipe and equipment shall not be
fireproofed. The entire beam shall be blast cleaned per Section 7.2 and primed with SigmaCover
280 per Section 8.3. Top face including the edges shall be masked off during fireproofing
application. All surfaces except top face and top edges shall be fireproofed with Pitt-Char XP per
this specification. The top face and edges (Non-fireproofed surface) shall receive one coat of
Amerlock 400 GF, 8-12 mils (200-300 mcrons) MDFT and top coat of either Sigmadur 550 (gray)
or Amercoat 450H, 2 to 3 mils (50 to 75 microns) MDFT. These coatings shall be applied after
Pitt-Char XP application.
1.5 All horizontal finished surface of fireproofing such as column base plate, top face of bottom
0
flange on beams, etc. shall have 5 slope to prevent water ponding.
1.6 Fireproofing zone of galvanized columns shall be sweep blasted per Section 7.3 and primed with
SigmaCover 280 per Section 8.3 prior to application of Pitt-Char XP.
1.7 Galvanized bolt on bolted connection shall be solvent wiped and surface shall be abraded with
80 grit sand paper, dust removed prior to application of SigmaCover 280 primer and finish off
with Pitt-Char XP and approved top coat system. This application can be combined with
fireproofing of field block outs.
2.0 Applicator’s Responsibility
Applicator QA/QC responsibilities as follows
a. Supply the equipment for the specified inspections and tests required for fireproofing activities.
b. Supply new and undamaged fireproofing materials received at the shop or field jobsite in the
manufacturer’s original sealed containers.
c. Proper storage of all materials in the area protected from weather before and during application
d. Inspection of fireproofing materials and accessories prior to commencement of work. Any material
that has been damaged or found to be defective shall be removed and replaced by the seller at his
expense.
e. Inspection during key construction phase include, proper storage of materials, surface preparation,
primer application, equipment setup and application (Pitt-Char XP), Installation of reinforcing mesh
(Galvanized Steel), Pitt-Char XP thickness measurements and topcoat application.
f. Applicator shall ensure that the applicator conforms to latest QC Manual. This included (sample
attached to this specification)
Pitt-Char XP Customer / Applicator Area QC Report
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Pitt-Char XP Reference Smple

Pitt-Char XP Plural Equipment Daily Report
Pitt-Char XP Daily Log
3.0 Manufacturer Responsibility
A technical service audit shall be conducted by the manufacturer during the initial start of fireproofing
and provide technical assistance during production phase.
4.0 Submittals
4.1 Applicator shall submit to the buyer a list of materials to be used in fireproofing and shall identify
the specific design mix including manufacturer’s datasheets and MSDS sheets.
4.2 Applicator shall submit written procedures for storage, handling, surface preparation,
environmental control, application, verification of fireproofing thickness, repair, and inspection of
the fireproofing. Procedures shall be submitted to Purchaser for review and approval prior to
using them.
4.3 Subcontractor shall submit to Purchaser for review fireproofing verification forms as specified in
clause 2.0 (f). Daily inspection forms shall be accessible for spot review on a daily basis.
4.4 Fireproofing verification forms shall be used to verify that proper materials were used, and that
accepted application procedures and specifications were followed. Fireproofing verification forms
shall include a statement of completion conformance.
5.0 Materials
5.1 General
Fireproofing materials shall conform to PPG Industries Pitt-Char XP Application Manual.
5.2 Primer
a. Primer shall be PPG SigmaCover 280.
b. Mid coat for top face of flange on beam PPG Amerlock 400GF
c. Primer shall be approved and UL 1709 tested.
5.3 Pitt-Char XP
5.2
5.3
5.3.1 Fireproofing shall be Pitt-Char XP manufactured by PPG Industries Inc.
5.3.2 Pitt-Char XP shall meet the requirements of UL1709, per XR 612.
5.3.3 Fire rating of Pitt-Char XP shall be 2 hour per UL1709 in accordance with Pitt-Char XP
Design XR 612
5.3.4 Pitt-Char XP shall have the following minimum physical properties:
3
a. Dry density – 68 lb/ft
b. Compressive strength – 2264 psi (determined in accordance with ASTM D695)
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c. Hardness – Shore D 35 when fully cured (determined in accordance with ASTM

D2240)
d. Flame spread – Class A 15 (determined in accordance with ASTM E84)
e. Smoke developed – Class A 70-110 (determined in accordance with ASTM E84)
f. Impact Strength – 1.46 ft. lbs/in (determined in accordance with ASTM D265 “A”)
g. Adhesion strength to steel – 750 psi (determined in accordance with ISO 4624 for
film thickness <2mm, unreinforced))
Testing shall be performed to determine physical properties for above items a, b, c, f, and g.
1.
2.
3.
4.
5.
5.4 Reinforcing Mesh
1. Reinforcing mesh shall be galvanized steel hardware cloth ½” x ½” x 19 gage.
2. Reinforcing mesh shall be obtained locally or as required by applicator.
5.5 Topcoat
1. Topcoat shall be Sigmadur 550 (gray) or Amercoat 450H at 2-3 mils DFT.
2. Finish color shall be Medium Gray per RAL 7004.
6.0 Preconstruction Activities
6.1 Preconstruction Meeting
6.1.1 Project Engineer shall arrange for a preconstruction meeting with the following
individuals in attendance:
a. Purchaser Project Engineer (primary project contact)
b. Purchaser Non Metallic Technologist
c. Purchaser Lead Civil Engineer
d. Purchaser QA/QC Inspector
e. Subcontractor representatives, including QC coordinator and foreman assigned to
the job
f. Contractor structural steel fabrication/erection representative
g. Manufacturer representative
6.1.2 Agenda to be covered at the preconstruction meeting shall include the following:
a. Review of Contractor’s submittals and this specification
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b. Inspection hold points

c. Controls of environmental conditions in the shop
d. Condition of steel necessary to accept fireproofing
e. Surface preparation and compatible primer application
f. Fireproofing application, installation of reinforcement, and thickness measurements
g. Cure measurement prior to application of topcoat
h. Proper topcoat application
i. Exposure to elements only after system is completely sealed
6.2 Sample Preparation and Adhesion Testing
1. Applicator shall prepare a fireproofing sample on a 6 ft. long W10x49 carbon steel beam and
two 6” x 6” x ¼” minimum carbon steel plates. The sample shall have pockets and tabs to
represent complex shape. All samples shall be blasted, primed and top coated per project
specification.
2. Sample requires inspection and approval in writing by the Purchaser before the Applicator
proceeds with application of the fireproofing.
3. Sample shall illustrate correct fireproofing appearance, thickness, reinforcing, and surface
finish, and shall be used as the application standard.
4. Carbon steel plate samples minimum 6” x 6” x ¼” shall be tested for adhesion in accordance
with D4541 on unreinforced Pitt-Char XP only. Plates shall have surface preparation similar
to beam with Pitt-Char XP applied to a maximum thickness of 2mm.
a. Adhesion of primer to steel or galvanizing shall be a minimum of 300 psi.
b. Adhesion of fireproofing to primer shall be a minimum of 300 psi.
c. Adhesion of topcoat to fireproofing shall be a minimum of 300 psi.
5. Owner or his representative, Contractor, Subcontractor, and Manufacturer shall approve the
sample.
6. Two random production pieces that are shop fireproofed shall also be tested for adhesion.
6.3 Area Inspection
Area that will receive fireproofing shall be inspected to verify that ducts, piping, equipment, or
other items that would interfere with application of fireproofing are not positioned until
fireproofing work is complete.
7. Substrate Inspection and Preparation
7.1 Inspection
1. Substrate shall be inspected to verify that it is ready to be cleaned/blasted.
2. Substrate shall be uniform and free of defects, such as weld deficiencies, lack of seal
welding, and poor drainage of galvanizing.
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3. Any substrate defects that may adversely affect adhesion or performance of the fireproofing
shall be properly repaired.
7.2 Non-Galvanized Substrate
1. Non-galvanized substrate shall be blasted in accordance with SSPC SP-10.
2. Blasted substrate shall have an anchor pattern of 2.0 to 3.0 mils minimum.
3. Specific abrasive shall be determined by the Applicator and approved by the Manufacturer
prior to use.
7.3 Galvanized Substrate

1. Galvanized substrate shall be cleaned and degreased in accordance with SSPC SP-1.
Alkaline cleaners shall not be used.
2. Cleaned substrate shall be blasted in accordance with SSPC SP-7/NACE No. 4. Abrasive
shall conform to SSPC AB-1.
3. Blasted substrate shall have an anchor pattern that is sharp with no evidence of a polished
surface.
8. Fireproofing Application
8.1 Ambient Considerations
1. Fireproofing shall be applied when:
a. Substrate temperature and ambient temperature are on the rise and greater than 50°F.
b. Ambient temperature is 5°F above the dew point.
c. Relative humidity is less than 85%.
2. Areas where fireproofing is applied shall be ventilated for 24 hours after application.
3. Work area shall be kept clean and well ventilated.
4. Spillage and over-spray shall be removed promptly before material has cured.
8.2 Protection of Adjacent Areas
1. Adjacent equipment and surfaces that will not be fireproofed shall be protected from damage
by over-spray, fall-out, or dusting.
2. Ducts in areas where fireproofing is being applied shall be closed and sealed.
8.3 Primer Application
1. Primer shall be applied to a dry film thickness (DFT) of 2 to 3 mils. Maximum allowable DFT
on overlaps shall be 3 mils.
2. For non-galvanized substrate, primer shall completely cover the blast profile.
3. Prior to application of primer, on galvanized substrate, excessive zinc thickness may be
reduced by sanding with P80-P-100 grade aluminum oxide abrasive paper for small areas.
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Polishing shall be avoided. For large surfaces, galvanized surface shall be sweep blasted
per SSPC-SP7
8.4 PITT-CHAR XP Mixing
1. Properly mixed PITT-CHAR XP is a medium gray (with no striping).
2. A quality control check for mixing shall be a ratio check, performed by the Subcontractor.
The ratio check shall be by weight as follows:
a. Weigh clean empty Parts A and B containers and note the respective weight.
b. Place the container under the ratio check valves located on the mixing block and open
the valve at exactly the same time under 2000 psi pump pressure or as required to give
a slow steady flow.
c. Close the valves when the containers are at least half full at exactly the same time.
d. Calculate the ratio of Part A and Part B as a percentage of the total weight. Example
Part A to Part B ratio is 3.25:1. Acceptable range is from 2.93 to 3.58:1.
3. A minimum of two ratio checks shall be performed per shift, (1) start of the shift and (2)
when the pump is shut down and restarted.
8.5 PITT-CHAR XP Application
1. Primer shall be allowed to cure for a minimum of twelve hours at 77°F before the PITT-
CHAR XP is applied.
2. Before PITT-CHAR XP is applied, primed substrate shall be cleaned of dirt, dust, grease, oil,
loose material, or other matter that may adversely affect PITT-CHAR XP bond.
3. PITT-CHAR XP shall be applied in accordance with PITT-CHAR XP project Manual.
4. PITT-CHAR XP materials shall be kept within a temperature range of 86°-93°F for 24 hours
prior to use with a plural pump with heated holding tank.
5. PITT-CHAR XP shall be applied using plural component spray equipment from PPG
approved suppliers; Spray Quip Inc., Spraypump, Airtech or Covercat.
6. Operating parameters for plural component spray equipment shall be in accordance with
current Project Application Manual.
7. PITT-CHAR XP shall be applied to a minimum thickness of 13.2 mm per UL Design XR 612
for 2 hour rating (UL 1709 certification directory).
a. Minimum thickness at any one point shall not be less than 85% of specified thickness.
b. Overall average thickness shall be equal to, or greater than, the UL specified thickness.
c. UL certified thickness is based on the average thickness.
8.6 Reinforcing Mesh Application
1. Reinforcing mesh shall be cut and bent to fit the flange thickness plus 5-6mm coating
applied and cured (1 coat) before the Pitt-Char XP is applied.
2. Mesh sections shall be cut from a roll 2, 3 or 4 foot wide and bent on a 4 ft wide minimum
brake to ensure straight crisp bends. The ½ x ½ x 19 gage galvanizes steel mesh shall be
Document No.:
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bent to fit 2-4 inches from flange edge toward the web in a “U” shape per attached drawing.
The bent mesh sections will be attached using a friction fit method on full flanges.
3. 3 sided beams shall have the inner top flange meshed by laying the uncoated flange facing
down, fireproofing the 3 sides and lying in the flat mesh sections onto the first coat of Pitt-
Char XP before cure. An option for pre erected 3 sided steel beams is to attach weld pins
2mm diameter x 25-50mm long in two rows 300mm centers on each half flange face to
secure the mesh in an inverted position after the first coat of Pitt-Char XP has cured by
bending the pins over the mesh to secure.
4. Adjacent pieces of steel mesh shall be butt joined at seams with a 25mm maximum gap.
5. Mesh shall be installed after approximately 5-6mm of Pitt-Char XP has been applied.
6. Second coat of Pitt-Char XP shall be troweled or rolled into mesh to ensure complete
encapsulation with no voids or mesh edges protruding from the coating.
8.7 Topcoat Application
1. Topcoat of either Sigmadur 550 or Amercoat 450H shall be applied per PPG
recommendation.
2. Unless otherwise specified, topcoat shall be applied within seven days after the PITT-CHAR
XP is applied. If the seven days are exceeded, the surface of the PITT-CHAR XP shall be
sweep blasted or mechanically abraded with 40 grit paper (or equivalent) and solvent
cleaned prior to applying the topcoat.
3. Topcoat shall be applied to a minimum DFT of 2 to 3 mils.
9. Inspection, Testing, and Repair
9.1 Daily Production Samples and Tests
1. Daily production samples shall be taken one per shift. Additional samples shall be taken if
material batch numbers change. This can be accomplished by spraying material into a
plastic cup and identifying sample number and date.
a. Samples shall be tested randomly to determine fireproofing hardness and density
properties.
b. Sample shall be documented on the PITT-CHAR XP Fireproofing Daily Log.
2. The following inspections and tests shall be performed on a daily basis.
a. Degreasing stage – surface contamination – Visual, white cloth check for oils or other
harmful contaminates [SOVENT WIPE TEST]
b. Blast cleaning – Visual inspection to ensure sheen surfaces are dulled by sweep
blasting steel [VISUAL]
c. Primer – Wet film thickness measurements primer [WET FILM GAGE]
d. Inspect spray equipment – Operating conditions of plural component equipment
[MATERIAL RATIO WEIGHT CHECK]
e. Application of PITT-CHAR XP – Inspect wet film thickness with approved wet film probe
[Bridge Gage], observe mesh installation
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f. PITT-CHAR XP dry film gage [Elcometer or similar] capable of measurements for the
specified Pitt-Char XP thickness and a calibrated probe such as a digital caliper to be
inserted in a predrilled 1/8” hole or as required to measure steel meshed areas.
g. Inspect cure of PITT-CHAR XP – [DUROMETER SHORE D]
h. Topcoat – Inspect application of topcoat [WET FILM THICKNESS / visual after cure)]
i. Environmental test equipment – Sling pychrometer, surface thermometer
9.2 Deficiency Inspection and Repair
1. Deficiencies in the fireproofing shall be inspected, noted, and properly repaired.
Deficiencies include, but are not limited to, the following:
a. Cracks or seams of any length in PITT-CHAR XP.
b. Disbondment of primer, PITT-CHAR XP, or topcoat
c. Exposed reinforcing mesh
d. Inadequate fireproofing thickness.
e. Excessive mills and subsequent coating runs, drips, spills, and curtains.
2. Repair of deficiencies shall conform to procedures as stated in the project Pitt-Char XP
Manual. If necessary, manufacturer shall write a repair procedure not cover in the Manual.
3. A written repair procedure shall be submitted to the Purchaser before repairs are performed.
9.3 Hardness Test
1. PITT-CHAR XP shall have a minimum Shore D value 24 hours after PITT-CHAR XP
application of 25 and >35 before application of the topcoat.
2. Shore D Hardness test shall be performed using a Shore D gauge.
3. PITT-CHAR XP shall have a fully cured Shore D value greater than 35.
4. Hardness readings shall be taken on areas that are relatively smooth.
5. Ten readings shall be taken per area, discarding the low and high reading.
9.4 Density Test
1. Random daily production samples (see 8.1) of PITT-CHAR XP shall be tested for density a
minimum of once per week.
3
2. PITT-CHAR XP shall have a minimum density of 68.7 lbs./ft .
9.5 Final Inspection
Final inspection of the installed fireproofing shall be performed jointly by the Applicator and the
Purchaser.
9.6 Test Results
Test results shall be recorded on “PITT-CHAR XP Customer / Application Quality Control
Report” and the “Fireproofing Daily log”.
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10. Curing
Fireproofed surfaces shall not be exposed to the exterior elements until the fireproofing is completely
cured and the topcoat is properly sealed over the entire fireproofed surface.
11. Shipping and Handling
All fireproofed steel shall be handled using nylon slings or other approved lifting methods. Proper
dunnage during transport, storage and jobsite erection shall be used to minimize damage to the
fireproofing. Large heavy steel sections should be lifted with sling on block out areas or lifting points to
avoid edge damage to fireproofing.
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Attachment A Customer Applicator Inspection Quality Report
Project: Report By: ______

Client: Title:
Clients Rep.: Date:
Applicator: Area:
Procedure below must be signed off by client and applicator.
Acceptance Applicator Client
Procedure Date Acceptance Acceptance Comments
Pin Installation ___________ ____________
Blasting ____________
Priming ____________
Primer Thickness
Mesh Installation ____________
Surface Acceptance ____________
Pitt-Char XP Coating
1st Coat ____________
2nd Coat ____________
3rd Coat ____________
Topcoat ____________
General
Comments:_________________________________________________________________
__________________________________________________________________________
Area Complete
Signature (Applicator): Date
Area Accepted
Signature (Client): Date
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Attachment B
PITT-CHAR XP® COATING DATE____________

REFERENCE SAMPLE APPROVAL
PROJECT:
LOCATION:
APPLICATOR:
DESCRIPTION OF SAMPLE:
LOCATION OF SAMPLE:
APPLICATION EQUIPMENT (  ): PLURAL AIRLESS ( ) SINGLE POT ( )
HAND TROWEL ( )
PITT-CHAR THICKNESS: (mm) (inches)
REINFORCEMENT TYPE (): FIBER GLASS MESH ( ) CARBON MESH ( )
STEEL MESH ( ) PINS/WASHERS ( )
SURFACE FINISH () : ROLLED ( ) SPRAY ( )
FINISH DESCRIPTION:
APPROVAL SIGNATURES
SIGNATURE TITLE COMPANY DATE

APPLICATOR
FABRICATOR
CLIENT
OTHER
PPG
FORM # 4 REVISED 3/97
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Attachment C:
Plural Spray Equipment Report
Customer: Date:
Location: Applicator:
Project: Report by:
Plural Fireproofing Equipment
Machine Type
Hose length
Preloading Pitt-Char XP temperature Part A: Part B:
Tank Temperature Part A: Part B:
Tank Pressures Part A: Part B:
In-line heater temperatures Part A: Part B:
Displacement pump pressures Part A: Part B:
Line Heat
Gun exit temperature

Spray gun tip size:
NOTES
Signature Site manager - Site QA/QC

Manager
Document No.:
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Attachment D
Daily Application Log
Customer: Date:
Location: Applicator:
Project: Report by:
Personnel
Site Manager: Foreman:
Weather Data
Wet Dry Surf. Dew
Time Air Bulb Bulb % RH Temp. Pt. Plus/Minus Conditions
Structures Coated Coating Thk. (mils) Reinforcement
Material Temperature ºC Component A: Component B:
Batch Numbers and Quantity

Component A Number Pails Component B Number Pails
Type of Spray Equipment:

Surface Preparation:
Primer / Thickness (mil)
Topcoat / Thickness (mil)
Pump Ratio (Plural)

Time "A" Weight "B" Weight Pump Ratio A:B
Document No.:
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Attachment E
Fire Resistance Ratings - ANSI/UL 1709
See General Information for Fire Resistance Ratings - ANSI/UL 1709
Design No. XR612

May 03, 2011
Ratings — 1, 1-1/2, 2, 2-1/2, 3, 3-1/2 and 4 Hr (See Item 3)
1. Steel Column — Min size W10x49 (min. W/D = 0.84, min. Hp/A = 159). The column surfaces
shall be free of dirt, loose scale and oil. Steel surfaces to be primed with polyamide-epoxy or
zinc rich primers to an approximate dry film thickness of 0.003 in.
2. Reinforcing Mesh — Carbon fiber mesh with a 1/4 by 1/4 in. sq pattern (four squares per
inch) weighing 2 oz/sq yd, wrapped around the column flanges and flange tips. Mesh
embedded at approximately mid-depth of mastic coating. Long direction of mesh installed
lengthwise along column, with joints overlapped min. 2 in.
2A. Glass Fiber Mesh — As an alternate to Item 2 for the 1 hr rating only, glass fiber mesh, 6
in. wide, weighing 4.5 oz/sq yd embedded at approximately mid-depth of mastic coating.
2B. As an alternate to Items 2 and 2A, — 1 in. hexagonal wire mesh (No. 20 SWG galv steel
wire), wrapped around the column flanges and secured in position by means of Type C furring
clips spaced approximately 12 in. apart. Mesh embedded at approximately mid-depth of the
coating.
2C. As an alternate to Items 2, 2A and 2B, — 1/2 by 1/2, No. 19 SWG galv steel welded wire
mesh. Butt ended mesh bent to fit tightly over the flange edges along the column length. Galv
or stainless steel flange edge clips shall be used when the required coating thickness exceeds
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0.50 in. The clips shall be placed at ends of mesh and shall be spaced a max 24 in. OC. The
mesh shall be fastened together across the flange faces with galv wire of 22 gauge or larger.
2D. As an alternate to Items 2, 2A, 2B and 2C, — 1-1/2 in. by 1-1/2 in. welded steel hardware
cloth formed from No. 20 MSG hot dipped galv steel wire or 1/2 by 1/2, No. 19 SWG galv steel
welded wire mesh. Mesh secured to the column with 5/16 in. wide by 3/16 in. deep steel
staples formed from 0.024 in. thick galv steel. Mesh placed at approximately mid-depth of the
coating and extending 2 in. to 4 in. from flange tips on flange faces.
2E. As an alternate to Items 2, 2A, 2B, 2C and 2D, — No. 20 SWG galv steel wire twisted to
form 1 in. hexagons or 1/2 by 1/2, No. 19 SWG galv steel welded wire mesh. Mesh placed at
approximately mid-depth of the coating and extending 2 in. to 4 in. from flange tips on flange
faces.
2F. As an alternate to Items 2, 2A, 2B, 2C, 2D and 2E, — 1/2 by 1/2 in. No. 19 SWG galv steel
welded wire mesh, approximately 8 in. wide, centered over flange edges and bent over 10
SWG wire spacers. Spacers installed across each flange on nominal 18 in. centers. Mesh
fastened in place at each spacer with 10 SWG formed wire clip.
3. Mastic Coating* — Coating spray applied directly from containers to the appropriate
thicknesses shown in the table below.
Rating Hr. Material Thickness, in. Material Thickness, mm

1 0.28 7.1
1-1/2 0.40 10.2
2 0.52 13.2
2-1/2 0.63 16.0
3 0.75 19.1
3-1/2 0.84 21.3
4 0.90 22.9
PPG INDUSTRIES INC — Type Pitt-Char XP
*Bearing the UL Classification Mark
Last Updated on 2011-05-03
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Date: 29-JUL-2011
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Attachment F
UL Steel Mesh Installation for 1.5-3 hour 1709 rating

Fireproofing Specification

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FIREPROOFING SPECIFICATION

CB&I CONTRACT NO. 166000

0 24-Mar-08 ISSUED FOR DESIGN TAA KRS KRS

1.3 Seller Responsibility

API American Petroleum Institute

Std. 318 Building Code Requirement for Reinforced Concrete

2.1 International Protective Coating / Akzo Nobel

3.1 Hazardous Equipment and Piping

3.2 Hazardous Area

3.3 Fire Protection (Fire rating)

4.1 Extent of Fireproofing

equivalent to the conditions of UL 1709. If activation of these emergency systems would

6.2 Lightweight Cementitious Products

6.3 Intumescent Mastic (See Appendix A and B for Material Requirements)

6.5 Waterproof Mastic

7.1 Concrete Fireproofing

7.2 Lightweight Cementitious Fireproofing

FIREPROOFING STEEL STRUCTURES

STRUCTURAL STEEL PIPE AND EQUIPMENT SUPPORT

4. WELDED WIRE MESH SHALL BE USED IN LIEU OF HEXAGONAL POULTRY MESH AS

FIREPROOFING DETAILS USING SPECIAL MATERIALS

FIREPROOFING DETAILS FOR VESSEL SKIRTS

APPENDIX A – APPLICATION OF INTUMESCENT FIREPROOFING USING CHARTEK 1709

Chartek Fireproofing Equipment Quality Control Report

f. Smoke developed – Class A 300 (determined in accordance with ASTM

i. Exposure to elements only after system is completely sealed

ATTACHMENT A – CHARTEK® FIREPROOFING – AREA QUALITY CONTROL REPORT

Owner’s representative: Applicator’s representative:

OPERATION DATE Nº TEST ACTIVITY SIGNATURE SITE COMMENTS

Applicator: Signature: Name:

Owner: Signature: Name:

ATTACHMENT B-CHARTEK® FIREPROOFING DAILY LOG

Owner’s representative: Applicator’s representative:

Area identification: see attached drawing

ATTACHMENT C- CHARTEK® FIREPROOFING EQUIPMENT QUALITY CONTROL REPORT

Owner’s representative: Applicator’s representative:

Area identification: see attached drawing

Report Nº: XXX – C Date: Prepared by:

PLURAL COMPONENT SYSTEM

Preloading Chartek temperature Part A: Part B:

Tank temperatures Part A: Part B:

Tank pressures Part A: Part B:

In-line heater temperatures Part A: Part B:

Displacement pump pressures Part A: Part B:

Signature Site Manager-Site QA/QC Manager:

ATTACHMENT D – UL Certification of Chartek 1709

Fire Resistance Ratings - ANSI/UL 1709

ATTACHMENT E – Installation Details

ATTACHMENT E – Installation Details (Continue)

ATTACHMENT E – Installation Details (Continue)

APPENDIX B – APPLICATION OF INTUMESCENT FIREPROOFING USING PITT-CHAR XP

Pitt-Char XP Reference Smple

c. Hardness – Shore D 35 when fully cured (determined in accordance with ASTM

b. Inspection hold points

7.3 Galvanized Substrate

Attachment A Customer Applicator Inspection Quality Report

Project: Report By: ______

PITT-CHAR XP® COATING DATE____________

SIGNATURE TITLE COMPANY DATE

Plural Spray Equipment Report

Preloading Pitt-Char XP temperature Part A: Part B:

Tank Temperature Part A: Part B:

Tank Pressures Part A: Part B:

In-line heater temperatures Part A: Part B: